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Hofmann geodyna 7750-p Service Manual

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Summary of Contents for Hofmann geodyna 7750-p

  • Page 1 7750-p Service Manual...
  • Page 2 BLANK PAGE__________________________________________________________________________...
  • Page 3 TABLE OF CONTENT 1. INTRODUCTION GENERAL TOOLS REQUIRED IMPORTANT SAFETY INSTRUCTIONS ELECTRICAL SAFETY PRECAUTIONS 2. AC/DC POWER DISTRIBUTION LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE ELECTRICAL REQUIREMENTS AC THEORY OF OPERATION DC THEORY OF OPERATION FUNCTIONAL DESCRIPTION INSTALLATION PRECAUTIONS (Floor Level) 3. BALANCER COMPONENTS INTRODUCTION LCD TOUCH BOX POWER ENTRY MODULE (PEM)
  • Page 4 4.24 CHECK AND REPLACEMENT OF HOOD SWITCH AND CAM 4.25 LASER POINTER: CHECK AND REPLACEMENT 4.26 SONAR SENSOR: CHECK AND REPLACEMENT 4.27 TRANSFORMER: CHECK AND REPLACEMENT 4.28 RECTIFIER BRIDGE: CHECK AND REPLACEMENT 4.29 WHEEL LIFT BOARD: CHECK AND REPLACEMENT 4.30 WHEEL LIFT POTENTIOMETER: CHECK AND REPLACEMENT 4.31 UPPER LIMIT SWITCH: CHECK AND REPLACEMENT...
  • Page 5 1. INTRODUCTION 1.1 GENERAL This Service Manual describes maintenance, checks and repairs operations of the wheel balancer and is for use of qualifi ed personnel only. Keep this manual constantly updated by adding Service Bulletins. IMPORTANT! The identifi cation datas of each machine are printed on an adhesive label attached to the rear or the left side of the machines.
  • Page 6 Geodata calibrator adapter # EAC0100G88A. Use this adapter to calibrate the Geodata only on balancers with Alloy Vibratory System. Service Code C80. This is required after: Ø Geodata potentiometer/s replacement Ø Geodata arm or arm components replacement. Ø Calibration of Geodata Ø...
  • Page 7 Eectronic inclinometer and spirit level...
  • Page 8 1.3 IMPORTANT SAFETY INSTRUCTIONS The units are CE or UL approved, but whenever using this equipment basic safety precautions should always be followed, including the following: Read all instructions. Do not operate equipment with a damaged power cord or if the equipment has been damaged until it has been examined by a qualifi...
  • Page 9 2. AC/DC POWER DISTRIBUTION 2.1 LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE 1. Notify all aff ected employees that a lockout or tagout system is going to be utilized and why. The authorized em- ployee should know the electrical power the machine uses and it’s hazards. 2.
  • Page 10 2.4 DC THEORY OF OPERATION LCD TOUCH BOARD The LCD touch processor board integrates the following sections: Ø CONTROLLER: Contains the kernel and manages all the balancer operation and data processing. Ø POWER SUPPLY: Provides operating voltage for the controller section, 5 VDC and to all the auxiliary devices. Ø...
  • Page 11 The frequency of the DC square wave generated by the encoder allows the balancer to compute shaft speed, wheel acceleration and weight location. The encoder and transducer signals are multiplexed by the CPU section of the IBP2, to give weight amount and location readings. The CPU section gathers the information generated from the encoder and transducer via a ribbon cable.
  • Page 12 3. BALANCER COMPONENTS 3.1 INTRODUCTION The balancer is manufactured with the following macro group components, that will be described in a deeper way in the next paragraphs. Ø LCD TOUCH BOX Ø LCD TOUCH SCREEN MONITOR Ø VIBRATORY ASSEMBLY Ø BRAKING SYSTEM Ø...
  • Page 13 Antenna WiFi Lead 1 and 2 geodata magnetic Lead 3 and 4 (+5V) micro switch wheel guard Lead 5 and 6 (+5V) for pedal switch pull Laser pointer zero mark Lead 7 and 8 VDC for wheel LED light X7 Diameter potentiometer Wheel lift board X6 Off...
  • Page 14 3.3 POWER ENTRY MODULE (PEM) The Power Entry Module (PEM) consists in two separated units instead of one. Ø One unit includes the switch only. Ø One unit includes the the power supply inlet, suppresses noise and contains the fuses.
  • Page 15 3.4 INTEGRATED CONTROLLER, POWER SUPPLY, SONAR SENSOR, LASER POINTER BOARD The wheel balancer is equipped with integrated LCD touch board that includes the controller, power supply and laser motor driver sections. The PCB board software loading or updating is done with a MMC/SD card. The replacement of the board always requires the software loading, balancer set up and calibration of the machine and it is mandatory to load the software with all connectors plugged to the PCB board.
  • Page 16 3.7 SIGNAL BOOSTER INTERFACE BOARD There are 2 Signal Booster interface board to make communicate the LCD touch screen to the LCD touch board. The boards have been provided to maintain the signal and voltage as much stable as possible due to long distance of the LCD Touch screen from the LCD Touch board.
  • Page 17 3.9 TRANSDUCERS Two transducers and the accompanying temperature sensor are used with all variants of the vibratory assemblies and they are installed in a manner that they form a virtual transducer on each end of the shaft. Both measuring transducers are arranged in one plane.
  • Page 18 3.11 INCREMENTAL ENCODERS An incremental encoder picks up the rotational travel, direction of rotation, and absolute angular position of a rotating shaft. One revolution is divided in increments (periods or intervals). The output signals A and B have about the shape and relationship shown. An intended irregularity (Nullmarke) is detected, with the main shaft rotating at constant speed.
  • Page 19 IMPORTANT: Before replacing the vibratory system due to suspected encoder ring malfunction try cleaning the encoder band. Please note: Do not use any cleaning agent (no alcohol, etc.) to clean the plastic polygonal ring! The red LED of the refl ective encoder IC does not light up immediately after power on, since voltage is applied under program control! In the very unluckely event that you will discover a defective polygon ring, the complete vibratory assembly has to be exchanged.
  • Page 20 With a single-phase squirrel cage motor with a nominal voltage of 230-volts AC and a maximum current of 4,5 A, the power requirements of the balancers can be easily met. It can be hooked up to 50 or 60 Hz line frequency via a plug to ordinary wall outlets.
  • Page 21 3.17 POWER CLAMPING DEVICE Description: The power-clamping device, moving the tie rod comprises of the following components: a) The axially bored main shaft with the tapered end, the MZV-p adaptor is fi tted on and tightened axially by two hexagon screws (13 mm across the fl ats) to the to bayonet disc. b) The tie-rod with a spline shaft as part of it, so axial moveable in the bore of the main shaft.
  • Page 22 3.18 INTERRUTTORE DI AUTO STOP GEODATA In the ALU-S mode, the operator is required to apply the adhesive weights in the exact position inside the wheel. Through the normal process, the wheel balancer receives input from the Geodata arm. The wheel balancer enters D1 (internal weight) and D2 (external weight) by the operator who pulls the Geodata arm in the positions where the weight will be applied.
  • Page 23 3.20 SONAR WHEEL DATA SYSTEM The sonar sensor device is used on some ranges of balancers to read the rim width. The sonar is a detector of distance and detect a possible return echo generated by the presence of an object within the nominal fl...
  • Page 24 3.23 WHEEL LIFT BOARD The wheel lift board communicates to the LCD touch board through the I2C bus, #9, and manages: Ø Input and output of 55VDC #1: It receives the 55VDC (J1+ and J2 gnd) from the rectifi er bridge and supplies the lift motor (J3+M and J4-M) Ø...
  • Page 25 Ø Wheel lift potentiometer, #5 Ø Lift knob sensors, #7 and #8. Ø Wheel lift buzzer, #9. Ø #A: Led LD1 of power supply. Ø #B: Led LD2 GREEN for the wheel lift lowering. Ø #C: Led LD3 RED for the wheel lift raising. The wheel lift board contains.
  • Page 26 4. SERVICE 4.1 INTRODUCTION This chapter will describe how to check and replace the components of the balancers described in Chapter 2 in the same order. NOTE: BEFORE OPENING THE MACHINE FOR SERVICE, DISCONNECT ELECTRICAL SUPPLY LINE AND USE THE LOCKOUT / TAGOUT PROCEDURE. 4.2 POWER SUPPLY CABLE: CHECK AND REPLACEMENT Ø...
  • Page 27 4.4 TO ACCESS TO THE LCD TOUCH BOX Ø : Big and Medium Phillipsscrewdriver, scissors, 5mm allen key. : 30’ Ø Disconnect the all cables from the back side of the LCD touch box. Ø Remove the weight tray. Ø Un-plug all of the harnesses from the LCD touch box marking each ones to ensure the correct installation. Ø...
  • Page 28 Check that there is continuity between terminals 1-2 and terminals 3-4 (W = 0 ~ 0.2) and discontinuity between terminals 1-3 and 1-4, as well as 2-3 and 2-4. TO REPLACE THE SWITCH: Ø Take the small fl at screwdriver and push the switch clips and at the same time push off...
  • Page 29 TO REPLACE THE NEW POWER ENTRY MODULE Ø Turn the balancer off . Ø Disconnect the power supply from the machine. Ø Remove the top cover from the IBP box Ø Disconnect the Power Entry Module from the main switch. Ø...
  • Page 30 4.9 CHECK AND REPLACEMENT OF THE LCD TOUCH BOX FUSE " : Multimeter, big and medium Phillips screwdriver, scissors, 5mm allen key. : 30’ : Defective fuses may cause the following malfunctions: Turning the machine on, the machine does not show anything. TO CHECK AND REPLACE THE FUSES Ø...
  • Page 31 4.11 CHECK AND REPLACEMENT OF THE LCD TOUCH BOARD " : Multimeter, 5.5 and 7mm tube type key, Medium fl at and phillips screwdriver, calibration rotor, touch less calibration tool, electronic or spirit inclinometer, scissors. : 1,5h : The defective LCD touch board may cause the following malfunctions: POWER SUPPLY SECTION •...
  • Page 32 TO CHECK THE CONTROLLER SECTION: Ø Make sure that the micro SD card is well fi xed into the slot of the board. Ø When installing the new panel make sure that the micro SD card is mounted in the slot and make sure it si well fi...
  • Page 33 DO NOT USE: 1. Cones that are worn or other wheel balancers. 2. Damaged sleeves or ring nuts, with loose handles, without handles, with handles secured with screws other than their own or ring nuts for other wheel balancers. 3. Pressure caps fastened to the quick release ring nuts and sleeves with adhesive tape, partially damaged, worn or for other wheel balancers.
  • Page 34 Ø Using 1/4”-6mm allen key, remove the six hex bolts to the vibratory. Pay special attention of spacer placement. Ø Lift up on the vibratory member and remove. Be careful not to damage wiring, boards, etc. Ø Set vibratory member into the balancer housing. Be careful not to damage wiring, boards, etc. Ø...
  • Page 35 Ø In order to assess the relevant insulation resistance; do not touch the machine, just read theindicated voltage. With the transducer in the humidity for several days, the insulation resistance can decline to less than 500 Meg Ohms. Insulation resistance of 500 Meg Ohms will produce 0.14 volts at the input of the analogue to digital converter.
  • Page 36 Ø With a screwdriver remove the collar of the transducer and disconnect the cables. Ø Cut the cables about 2mm under the old crimp. Ø Insert the wires into the transducers: the black band cables must be mounted on the positive connector (+). Ø...
  • Page 37 Remark: The tightening torque is necessary to ensure the correct preload to the spring plate. TO ADJUST THE REAR TRANSDUCER Ø Tighten the the M10x1setscrew at 0.50 ± 0,05 Nm (4,4 ± 0,4 lbs-in). Ø Fasten the locknut. To prevent the setscrew to turn, hold it with the hexagon wrench 5-mm inserted.
  • Page 38 Ø Remove the phillip screw holding the encoder PCB to the shaft tube. Ø Clean the encoder board lens Ø Clean the polygon ring. Ø Clean the polygon ring with humid or dry cotton bud. Use only water. Do not use alcohol glass cleaner, degreaser or any other aggressive liquids: This kind of substances are too aggressive for the polygonal ring.
  • Page 39 Ø Make sure that the optoencoder is well tightened. TO REPLACE OF THE POWER CLAMP ENCODER BOARD. Ø Disconnect power supply. Ø Remove weight tray. Ø Disconnect the 4 Pin ribbon cable from the optoencoder PCB. Ø Remove the phillip screws holding the encoder board to the bracket. Ø...
  • Page 40 Ø To adjust the gap unlock the screw shown by the arrow and then lock it fi rmly again. Ø After the blocking of the screw check again the gap Ø Connect the 4 pin ribbon cable to the encoder PCB. Ø...
  • Page 41 MOTOR ON SOLENOID BREAKE TO REPLACE THE MOTOR Ø Unplug the motor. Ø Remove the bolts securing the motor to the vibratory system. Ø Remove the setscrew securing the motor pulley to the motor. Ø Remove the pulley from the motor. Ø...
  • Page 42 4.19 CHECK AND REPLACEMENT OF THE POWER CLAMP NUT AND TIE ROD " : Medium Phillips and fl at screwdriver, 5 and mm allen key, 13mm end key, tire lever, scissors. : 2h : Defective power clamp may cause the following malfunctions: •...
  • Page 43 Ø Remove the 4 screws that secure the power clamp nut to the pulley. Slide the power clamp nut with the rod off through the hole of the plastici body. Ø Check if the tie rod and its guide on the vibratory system are fi ne. If the tie rod is worn out, replace the power clamp nut kit.
  • Page 44 4.20 CHECK AND REPLACEMENT OF THE ELECTROMAGNETIC BRAKE " : Medium Phillips and fl at screwdriver, Multimeter, 2,5, 5 and mm allen key, 13mm end key, seeger pliers, tire lever, scissors. : 2h : Defective electromagnetic brake may cause the following malfunctions: •...
  • Page 45 Ø Remove the collar and the drive pulley. Ø Remove the stator with the brakes. Ø Mount the new stator and the drive pulley. Ø Mount the collar and the C-clip. Ø Using a 2.5mm hex key securely tighten each set screw. This will push the pulley sheave to the right while the collar tightens securely against the C-Clip and will create a gap between the collar and the pulley sheave.
  • Page 46 4.21 CHECK AND REPLACEMENT OF ELECTRIC BRAKE / CLAMPING PEDAL SWITCH " : Medium and big Phillips screwdriver, 3, 5 and 6mm allen key, 10mm end key, scissors. : 2.5h : Defective mechanical brake cable may cause the following malfunctions: •...
  • Page 47 TO ADJUST AND REPLACE THE SWITCH Ø Remove the defective switch from the pedal. Ø Remove the weight tray. Ø Release the switches wires inside of the cabinet. Ø Cut the wires of the defective switch and connect them to those ones of the new switch. Ø...
  • Page 48 4.22 CHECK AND REPLACEMENT OF GEODATA DISTANCE POTENTIOMETER " : Medium and big Phillips screwdriver, 13 and 14mm end key, 3mm allen key, scissors. : 1.5h : Defective potentiometer may cause the following malfunctions: • Machine shows error E3. • Machine shows error 001040-001042-001046.
  • Page 49 Ø Hold the toothed wheel fi rmly, using a fl at blade screwdriver adjust the potentiometer referring to the paragraph of C code C80 Ø Route the belt over guide roller. Ø Connect the potentiometer to the LCD touch board. Ø...
  • Page 50 Ø Install potentiometer onto bracket and tighten 13mm nut. Make sure to insert the potentiometer antitwist pin through the squared hole of the cabinet. Ø Install cog wheel onto potentiometer shaft and hand tighten 10mm nut. Ø Attach SAPE harness to X7 connector of Processor Board. Ø...
  • Page 51 TO REPLACE THE SWITCH Ø Disconnect the power supply from the back of the machine. Ø Remove the weight tray. Ø Remove the cover plate from the wheel guard box. Ø Check the condition of the micro switch cable connectors. If they are oxidized, replace them. Ø...
  • Page 52 Ø Check if the cable and connector are fi ne. Ø Disable the laser pointer. Ø Take an alloy wheel and balance it with the Geodata. Ø Mark the position of the applied weights and then remove them. Ø Enable the laser pointer and check the aiming: if it is diff erent, perform a C122. TO REPLACE THE LASER POINTER Ø...
  • Page 53 TO CHECK THE SONAR: Make sure that the gauge arm is correctly calibrated taking rim data input of a wheel with steel rim or performing the C92 with the calibration rotor. If the rim data entry ARE NOT CORRECT, perform the C codes C80, C81 and C90. 2.1 Clamp the sonar calibrator and go to C82 and check if the sonar readings are correct and stable: a.
  • Page 54 Ø Turn counterclockwise the link to remove it from the sonar arm. Ø Replace the sonar. Ø Connect the cable. Ø Secure the sonar to its arm. Ø Tighten the link and fi x it to the wheel guard. Ø Pull the sonar cable into the box behind the machine and mount the cover.
  • Page 55 Ø If there is not any power supply go back to par. 4.5. Ø Remove the wires blue and green from the rectifi er bridge. Ø Using a VOM in VAC check for 36VAC at the output transformer terminals. Ø If there is not any power supply outgoing, the transformer is defective and must be replaced.
  • Page 56 Ø Turn the balancer on Ø Remove the weight tray. Ø Using a VOM in VDC check for 55VDC at the intput wheel lift board terminals. Ø If there is not any power supply incoming, switch off the wheel balancer and disconnect it from the power supply. Ø...
  • Page 57 Ø Position the black probe alternatively to the other rectifi er bridge plug. Ø Make sure that the Voltmeter will show a value similar to that one in the pictures...
  • Page 58 TO REPLACE THE RECTIFIER BRIDGE Ø Mount the new unit. Ø Connect all wires in the correct position. Ø Connect the power supply to the machine. Ø Turn the machine on and check if it works fi ne. Ø Turn the balancer off . Install the weight tray.
  • Page 59 Ø Turn off the balancer and disconnect it from the power supply. Ø Remove the weight tray. Ø Connect the power supply to the machine and turn it on. Ø Raise and lower the wheel lift with the buttons on the knob. Ø...
  • Page 60 WHEN PRESSING THE UP / DOWN BUTTONS, THE WHEEL LIFT DOES NOT WORK IN ONE OR BOTH DIRECTIONS, BUT WORKS SMOOTHLY BY PRESSING THE PEDAL Ø Check the status of the buttons and wiring of the control handle F4.33. Ø If the buttons and wiring are good, replace the board. THE WHEEL LIFT DOES NOT WORK IN ANY WAY AND E23 APPEARS.
  • Page 61 TO REPLACE THE WHEEL LIFT BOARD Ø Switch off the machine. Ø Disconnect the power supply from the machine. MPORTANT! BEFORE DISCONNECTING THE WIRES FROM THE LIT BOARD WAIT 2’ (MINUTES) TO DISCHARGE COMPLETELY THE CAPACITORS IN IT. Ø Disconnect all wires from the board. Mark the connectors in order to avoid mixing up at the mounting of the new board.
  • Page 62 Ø Place the terminals of the multimeter on the two outer terminals of the connector: the multimeter must show the value of the potentiometer. Ø Connect the wheel balancer and the lift to the power supply and switch them on. Ø...
  • Page 63 TO REPLACE THE POTENTIOMETER Ø Move the lift carriage to the right. Ø Remove 4 screws of the upper plastic guide. Ø Position a piece of wood under the lift table to hold it position after the removing of the securing screws. Ø...
  • Page 64 Ø Remove the 13mm nut holding the potentiometer to the bracket. Ø Install the new potentiometer onto bracket and tighten 13mm nut. Make sure to insert the potentiometer antitwist pin through the hole of the bracket. Ø Install cog wheel onto potentiometer shaft and hand tighten 10mm nut. Ø...
  • Page 65 4.31 UPPER LIMIT SWITCH: CHECK AND REPLACEMENT " : Medium Phillips screwdriver, Multimeter, tie wraps, scissors. : 1h : Defective switch may cause the following malfunctiions: • The wheel lift lowers only. • The wheel lift does not work at all. TO CHECK THE SWITCH Ø...
  • Page 66 Ø If the status is 0 with the microswitch pressed, position the terminals of the multimeter on those of the microswitch: if there is no continuity (no beep) the microswitch is broken. If there is continuity (beep) the microswitch is good. Check cables and wheel lift board.
  • Page 67 4.32 LOWER LIMIT AND FEET PROTECTION BOARD SAFETY SWITCHES: CHECK AND REPLACEMENT " : Medium Phillips screwdriver, Multimeter, tie wraps, 7mm tube type wrench, 7mm wrench, scissors. : 1,5h : Defective switch may cause the following malfunctiions: • Lowering the wheel guard the whell will not start and E2 is displayed. •...
  • Page 68 Ø Check if the green led of the relè is on. If it is off chek the lift low end stroke microswitches and their wiring F4.33. Ø Turn off the balancer and disconnetc it from power supply. Ø Disconnet the switch from the extension cord. Ø...
  • Page 69 Ø Place the leads of the multimeter on the black and gray wires of the low limit microswitch connector: there must be continuity and the multimeter must beep. By pressing the microswitch there must be no continuity and the multimeter must not beep. Ø...
  • Page 70 Ø Check the status of the "HANDLE"of the operating handle buttons. Ø Without pressure the state must be at 0. Ø By pressing the buttons of the operating handle one at a time, the status must show a value up to 99. Ø...
  • Page 71 Ø Remove the lifter's footboard handle. Ø Disconnect the button cable. Ø Remove the feet protection board. Ø Take the multimeter and select it in Ohms/beeper. Ø Check if there is continuity between the ends of each wire of the connectors cable.
  • Page 72 4.33 WHEEL LIFT MOTOR: CHECK AND REPLACEMENT " Medium Phillips screwdriver, Multimeter, tie wraps, scissors, 5 and 6mm allen wrench, hammer. : 2h : Defective switch may cause the following malfunctiions: 1. The wheel lift does not work. TO CHECK THE MOTOR Ø...
  • Page 73 Ø If the "Motor current" status remains at 0, or in any case at a value lower than 1A, it means that the motor is not powered correctly and therefore it is necessary to check the motor output on the board. Ø...
  • Page 74 TO REPLACE THE MOTOR Ø Turn off the machine Ø Disconnect the machine from the power supply. Ø Remove the lift table following 4.30. Ø Raise the lift up to end of stroke and block it with a piece of wood. Ø...
  • Page 75 4.34 UNLOCKING OF THE WHEEL LIFT WORM SCREW. " : 26 and 32mm wrenches. : 30’ i : Blocking of the wheel lift may cause the following malfunctions: • The wheel lift is blocked in home position. TO UNLOCK THE WHEEL LIFT Ø...
  • Page 76 5. TROUBBLE SHOOTING 5.1 INTRODUCTION This chapter represents a kind of trouble-shooting guide, which describes the diff erent typologies of error, all system messages available and the possible causes of malfunction. In particular the following are described: Ø Error Codes: an error code appears automatically on the screen when an error occurs; these codes are subdivided into H-code, E-codes and K-codes.
  • Page 77 5.3 IN THE FIELD REPROGRAMMING OF THE BALANCER After software down loading or LCD display panel replacement, perform service codes in the following order: • - Reset Counters • - Select machine model: after the selection, the machine will make three audible beeps followed by the automatic turning off...
  • Page 78 SONAR SENSOR • - Sonar sensor calibration status WEIGHT LASER BOARD • C123 - Weight laser board status POWER SUPPLIES STAUS • - Check lines Voltage • - Check Voltages of SAPE potentiometers (AD8, AD9, AD10) or perform STEP 1 of C80 and C82 •...
  • Page 79 5.6 "E" EEROR CODES A series of tests is accomplished after the machine has been turned on. If a test is not successful: • A series of audible signals is given • An error code is read out. A three-tone signal is given once if the machine is operative. In case there is a functional error it must be acknowledged by pressing the STOP key and there is no three-tone signal.
  • Page 80 Gauge arm not in home position Complaint After turning on the balancer show E3. Inner SAPE gauge arm not in home position. Weight tray not properly placed. Distance potentiometer not calibrated. Root cause Distance potentiometer disconnected from the IBP box. Difective distance potentiometer cable.
  • Page 81 Wheelguard is not open, wheel may not be clamped/unclamped Complaint Wheel clamping or unclamping is not allowed with the wheel guard lowered. Wheel guard lowered. Root cause Wheel guard switch cable disconnected from the IBP box Service Code Raise the wheel guard for Wheel Clamping or unclamping Actions to do Make sure abou the proper connection of the wheel guard switch cable The power clamping device is not clamped...
  • Page 82 Wheel lift not at home Complaint Clamping the wheel, the screen show E24 Wheel lift is not at home position The wheel lift motor is blocked Root cause The wheel lift is blocked The lower wheel lift switchs are diosconnected The wheel lift board is defective.
  • Page 83 The inner gauge arm for distance and rim diameter is defective Complaint After switching on the balancer, the screen shows E92 2D sape or geodata arm not in home position. 2D sape or geodata arm not calibrated. Distance and/or diameter potentiomer are unplugged. Root cause Distance and/or diameter potentiometer are reversed on the IBP box.
  • Page 84 E145 Contents of the EEPROMs are diff erent Complaint After switching on the balancer, the screen shows E145 Contents of both permanent memories are diff erent, but both contain valid data. Root cause EEprom of IBP box and Optoencoder are not matching each other. IBP box or Optoencoder have been replaced Service Code C74, C85, C86...
  • Page 85 E502 Laser Kit Motor Power Supply Fault Complaint Turning the machine on, the display shows E502 No power supply to the laser motor. Root cause Cable from IBP board to Laser motor is disconnected, missing or damaged. Defective Laser kit. Service Code C122, C123, C90 Check the proper fi...
  • Page 86 E800 Unable to connect WIFI network Complaint The screen shows E800 during the WiFi connection Root cause Missing WiFi communication Service Code Check if the WiFi device is correctly confi gured. check if the re is the signal and if it is stable. Actions to do Check the password Check if the antenna is connected.
  • Page 87 5.7 “H” ERROR CODES Optimisation Can't Improve Press ESC button and balance the wheel again without perform the optimization because the whe- el running conditions cannot be improved. Optimisation Not Recommended Further optimization not recommended but feasible Optimisation Recommend Minimisation Weight minimisation is recommended, optimisation can achieve no further improvement Power Clamp Disabled Enable power clamp...
  • Page 88 Invalid Sonar Value Raise the wheel guard and lower it slower Sonar has change acceleration during the lowering Raise the wheel guard and let low it itself Check the sonar cables. If the problem still persists: Check if sonar is well secured to the wheelguard. If the problem still persists: Check the gas spring.
  • Page 89 H948 Invalid Version BK Perform C48. H950 Software update via USB fl ash drive has failed Perform C50. Change the USB stick.
  • Page 90 5.8 ERROR CODES ON BOARD 0X001001 PO NOT FOUND Turn off and back on the machine. If the problem still persists: Load the software. If the problem still persists: Check the main shaft Optoencoder cable If the problem still persists: Check the main shaft Optoencoder.
  • Page 91 0X001005 PO EEP2 RD Turn off and back on the machine. If the problem still persists: Load the software. If the problem still persists: Replace the Optoencoder. If the problem still persists: Replace the LCD touch box. If the problem still persists: Call Snap On C Codes C74, C75, C85, C86, C122, C115, C84, C88, C90...
  • Page 92 0X001012 KEYBOARD READING The microprocessor has to fi nd the keyboard and communicate with it while balancer is working. If something is wrong with that this diagnostic codes is generated by balancing kernel software. I2C communication failure. Check the plugs, connectors and cable wiring from power interface board to the key board. May have to replace the integrated panel assembly if you can not fi...
  • Page 93 0X001024 NOISY SIGNAL FROM TRANSDUCERS DURING MEASURING RUN Check if the machine is well placed on the fl oor. If the problem still persists: Check if the balancer components vibrate. If the problem still persists: Check the belt tension. If the problem still persists: Check the bearings.
  • Page 94 0X001033 VCC BELOW LIMIT OF 5.2VDC Check VCC connectors and cables Check the power supply with C110. If the problem still persists: Check sonar sensor. If the problem still persists: Check the main shaft Optoencoder If the problem still persists: Check the IBP box If the problem still persists: Call Snap On...
  • Page 95 0X001038 MAIN SHAFT OPTOENCODER LED CURRENT ABOVE20 mA, TOO HIGH Check the main shaft Optoencoder cable. If the problem still persists: Clean the main shaft Optoencoder band. If the problem still persists: Check the main shaft Optoencoder. If the problem still persists: Call Snap On.
  • Page 96 0X001043 SAPE 2D HIGH VOLT Check the Diameter potentiometer connector and cable. If the problem still persists: Check the Diameter potentiometer If the problem still persists: Check the IBP box. If the problem still persists: Call Snap On C Codes C80, C81, C92, C115, C84, C88, C90 0X001046 1D SAPE INVALID CAL...
  • Page 97 0X001053 FAIL CAL USER Perform the User calibration If the problem still persists: Call Snap On C Codes 0X001054 VIRTUAL DIMENSION OUT OF RANGE Perform the calibration If the problem still persists: Check the transducers wiring. If the problem still persists: Check the transducers.
  • Page 98 0X001058 CAL2 0G WEIGHT HIGH Perform the calibration with C115. If the problem still persists: Check the transducers wiring If the problem still persists: Check the transducers adjustment. If the problem still persists: Check the IBP box. If the problem still persists: Call Snap On C Codes C66, C75, C103, C104, C115, C84, C88, C122, C90.
  • Page 99 0X001080 SPINUP TIMEOUT Check the belt adjustment. If the problem still persists: Check the belt. If the problem still persists: Check the brake adjustment. If the problem still persists: Check the motor connector and cable If the problem still persists: Check the motor pulley.
  • Page 100 0X001082 SPEED LOW Check wing nut If the problem still persists: Check the shaft. If the problem still persists: Check the wheel clamping. If the problem still persists: Check the belt adjustment. If the problem still persists: Check the belt. If the problem still persists: Check the brake adjustment.
  • Page 101 0X001085 SLIP DETECTED Check wing nut If the problem still persists: Check the shaft. If the problem still persists: Check the wheel clamping. If the problem still persists: Check the main shaft Optoencoder. If the problem still persists: Check the IBP box If the problem still persists: Call Snap On C Codes...
  • Page 102 0X001092 CLAMP MAX DISP Check the Power Clamp pedal. If the problem still persists: Check the drive Pulley Optoencoder If the problem still persists: Check the brake pads If the problem still persists: Check the electromagnetic brake If the problem still persists: Check the main shaft Optoencoder.
  • Page 103 0X001095 CLAMP SLIP Check the Power Clamp pedal. If the problem still persists: Check the drive Pulley Optoencoder If the problem still persists: Check the brake pads If the problem still persists: Check the electromagnetic brake If the problem still persists: Check the main shaft Optoencoder.
  • Page 104 5.9 STRUCTURE OF AN ERROR CODE A complete error code consists of 6 hexadecimal digits. Digit 6 Digit 5 Digit 4 Digit 3 Digit 2 Digit 1 Module ID Priority ID Error code Left Display Right Display The module ID is a 2-digit hexadecimal value and indicates the software module which detected the error. The priority ID represents the kind of error (message only, critical error).
  • Page 105 81X160 81X165 81X16A 81X161 81X166 81X16B K CODE 81X162 81X167 81X16C 81X163 81X168 81X16D 81X164 81X169 DESCRIPTION Communication with EEPROM through I2C bus is failed. When the microprocessor wants to calculate the unbalances, it needs a lot of data that EXPLANATION stored in EEPROM.
  • Page 106 5.13 MODULE “C” :HARDWARE TEST ERROR There is an error occurred during the hardware test. The four hyphens replace the digits 0 to 9 and the letters A to F which all characterize an error/defect. The following test will be performed: K CODE 0XC10F02 0XC10F07...
  • Page 107 K CODE 0XC10410 0XC10420 0XC10430 0XC10410: No signal output from transducer 1 (behind main shaft) DESCRIPTION 0XC10420: No signal output from transducer 2 (front of main shaft) 0XC10430: No signal output from both transducers There are two preloaded transducers connected to the IBP board. When the shaft spin with the wheel assembly, the imbalance produces vibration on these transducers.
  • Page 108 6. SERVICE CODES 6.1 INTRODUCTION The service codes are used to: Ø Calibrate module Ø Change setting. Ø Show and check measured values of screen of certain signals, system information. Ø Upgrade software 6.2 ENTERING SERVICE C CODES AND OPTIONS Ø...
  • Page 109 Ø Abort: The service menu can be exited by pressing "RETURN" key. The display is cleared and a beep is generated. Ø Special function: Press "SELECTION" key and turn the wheel or shaft to enable/disable extra functionality on some C codes (i.e. C74, C90, C98, C120) Press "RESET COUNTER"...
  • Page 110 6.4 SERVICE C CODES REFERENCES Display & clear error record Options: To clear the error memory click on the "RESET COUNTERS" button. Special function: none Description: The last 10 diff erent malfunction codes are written into the error memory so that they can be called up and reported by the operator of the wheel balancer e.g.
  • Page 111 Unbalance Calculation Parameters Options: None Special function: None Description: This C code defi ne the start mode and automatically the necessary number of revolution for measurement. The Special function can be read out one below the other: In step 1: The balancing time is reduce automatically in case the machine is able to measure it in the fi rsts revolutions of the spin.
  • Page 112 Description: The download operation is started by pressing the Acknowledgment key when the value is “1”. Make sure the machine is not shut down during download operations. Once download has been completed, the machine has an automatic reboot. Comment: No further action is required. Download of the UI software to the fl...
  • Page 113 • During Service Code C50, the system updates the compact fl ash installed on the board. After the rebooting the screen might show the error codes H948 and it is necessary to perform the following C code: C48 to update the Kernel. C46 to update the lift fi...
  • Page 114 Display of measured data/measurement statistics for the incremental encoder/code bar So that the Optoencoder unit and the code bar can be checked, the main shaft must rotate with constant speed. As proper performance of the Optoencoder unit is not ensured during execution of C54, speed and direction of rotation cannot be supervised.
  • Page 115 Reading Meaning Step 8 of Test function C54 active 8.__ Divergence between channel A and channel B __-_ ___A RH display is count of channel A ___B RH display is count of channel B Indication of the line voltage Options: None Special function: None...
  • Page 116 Indication of the temperature Options: None Special function: None Description: Indication of temperature in centigrade (°C) Comments: Please refer to error ID 580, 581, 585, 586 for the limits. Indication of the residual unbalance of main shaft compensated for using C84 Options: None Special function:...
  • Page 117 Indication of the correction factors for user calibration Options: None Special function: None Description: Indication of the correction factors for user calibration. The correction factors determined during user calibration are read out in form of 6 digits. SCREEN:The correction factors determined during user calibration for the rear and front transducer are read out in form of 6 digits.
  • Page 118 Comments: The options and the special functions are still available after braking the measuring run with the STOP key. The angular position of the unbalance will be displayed above the unbalance values. The C-Code will be exited by pressing the STOP key a second time. Indication of the transducer sensitivity as measured with code C83/C115 Options: None...
  • Page 119 Display phase stability of the vpm system as measured with C code 115 Options: None. Special function: None. Description: None Reading with screen balancers: 1. Field : distance-dependant phase shift of rear transducer 2. Field : phase shift between rear and front transducers. Comments: The shown values are those calculated in the latest calibration performed, not those saved from the latest C90.
  • Page 120 Set code C72. Press START key in order to initiate temporary compensation of unbalance. Insert the user calibration weight into the adaptor fl ange so that it extends to the left and press the START key. Insert the user calibration weight into the adaptor fl ange so that it extends to the right and press the START key.
  • Page 121 direction only after 2 turns backward à A and B channel signals are OK, synchronisation in backward direction is OK as well after 2 turns in each direction à A and B channel signals are OK, but synchronisation was made in backward direction only Incremental encoder was rotated by more than 2 turns in each direction and performs properly.
  • Page 122 Description: GEODATA ARM CALIBRATION ON ALUMINIUM VIBRATORY ASSEMBLY Step 1: Place the adapter on vibratory assembly. Move gauge arm to calibration position 1 and adjust diameter potentiometers mechanically: the voltage of the diameter potentiometer is indicated in the left 3-digit display. The voltage of the distance potentiometer is indicated in the right 3-digit.
  • Page 123 Step 2: Move gauge arm to calibration position 2. Gauge arm extended to 300mm. The reading must be: • 3.11V - 3.15V Press acknowledge key to confi rm step 2. Step 3: Move gauge head to calibration position 3 (notch in plastic adapter). Halfcone tip under gauge head placed on calibration notch of the thermo format adapter Press acknowledge key to confi...
  • Page 124 Comments: Save calibration data in the permanent memory using C90 code Measuring the adaptor fl ange and the zero plane Options: None Special function: None Description: To keep the machine operative and to allow width measurement in case the gauge arm is defective, the distance SAPE will be calibrated relative to the clamping surface of the adaptor on the condition that the gauge arm has already been calibrated.
  • Page 125 3. Position the electronic inclinometer on the calibration tool and rotate it untill to reach an inclination of 67.5° +/-0.5° from the vertical. Raise the wheel guard. Press “OK” key to begin the C82. Step 1 The screen shows the following values in the top line: BOX 1.
  • Page 126 Step 2 Lower the wheel guard. Then the sonar will try to acquire 3 valid measurement, in mm, emitting one beep every second: when acquired the screen will show the green arrows. Take a ruler and make sure that distance shown in the screen will be comparable with the one done manually.
  • Page 127 Calibration of the unbalance measurement with wheel/test rotor. Options: None Special function: In case of using of a wheel, use a 6.5”x15” steel rim with a maximum unbalance of 10g in each side. Description: With the calibration of the unbalance measurement the following are determined: the sensitivity of the transducers, the phase diff...
  • Page 128 ROTATE THE CALIBRATION TOOL / WHEEL WITH 100GR AT 12 O’CLOCK. Press the “ENTER” key to enter the value of the test weight. Step 3: Press the “START” button to begin the measuring run. Step 4: Remove the 100 gram calibration weight and insert it into the right hand plane of the Pruefrotor / wheel.
  • Page 129 Step 6: The ambient transducer temperature is displayed for 1 second. Step 7: Remove the 100 gram weight, lower the hood and press the “START” button to begin a measuring run. Step 8: . Insert the calibration weight that is supplied with the balancer on the left side of the backing plate.
  • Page 130 Compensation of unbalance of main shaft Options: None Special function: None Description: To save balancing of the main shaft by drilling out material or by adding balance weights, the residual unbalance of the main shaft is determined and compensated for (subtracted) in all subsequent measurement runs. Since the angular position of the drive pulley relative to the main shaft is random in the clamped state, the residual unbalances of main shaft and drive pulley have to be determined and stored separately.
  • Page 131 Comments: None Copy content of serial EEPROM (EEP) from optoencoder to IBP Options: No action Copy from optoencoder EEP to IBP EEP. Special function: None. Description: To make sure the content is not overwritten by mistake, fi rst set display from 0 to 1 by using the option selection.
  • Page 132 Press the “START” button to begin the measurement run. Step 2: Attach the 100 gram weight to outside of the Pruefrotor and press the “START” button. Step 3: Move the shaft to locate the 100 gram weight at “BOTTOM DEAD ENTER”...
  • Page 133 Description: 1. Field / left display : diameter (408-410) 2. Field / right display : distance (From machine to calibration rotor edge). Comments: Conditioning of the solenoid brake Options: None Special function: None Description: Conditioning of the solenoid brake (p-variants only) WARNING! With this test function the main shaft still rotates when the wheel guard is open.
  • Page 134 C103 Test of transimpedence and unbalance signal amplifi ers Options: all values in one screen. All values for channel 1 (1…6) on the left and for channel 2 (7…12) on the right. Description: This service code must be executed when the wheel balancer always chases the weight (weight chasing).
  • Page 135 Comments: None C110 Indication of the operating voltages supplied by the power supply module Options: None. Special function: None. Description: Indication of the operating voltage,5.0 VDC, supplied by the power supply module for the controller board Comments: Please refer to error ID 810 and 811 for the limits. C115 Calibration of the unbalance measurement with test rotor.
  • Page 136 Step 1: Press the “START” button to begin the measuring run. Step 2: If a Pruefrotor is used, screw the 100 gram weight on the left side of the Pruefrotor. If the value displayed is not “100” in step 2 press and hold the “ENTER VALUE” key (F4) and rotate the shaft until the custom weight is displayed.
  • Page 137 Step 5: . Step Number 5 has not been programmed. Press the “ENTER” key to advance to the Step 6: The ambient transducer temperature is displayed for 1 second. Step 7: Remove the 100 gram weight, lower the hood and press the “START”...
  • Page 138 Step 8: . Insert the calibration weight that is supplied with the balancer on the left side of the backing plate. Press the “START” button to begin a measuring run. CALIBRATION COMPLETE Comments: Save the calibration data in the the permanent memory using code C90. C120 Enable / disable the laser pointer Options:...
  • Page 139 Set rim dimensions using the gauge arm. Enter service code C122: The following screen are displayed: The laser pointer will shot the dot to the inner rim edge Rotate the wheel untill the laseer dot is in front of the adhesive weight. Adjust the laser dot position pressing left/right arrow button.
  • Page 140 Then the laser dot will move to the outer plane. 10. Repeat the same procedure as described above from point 7, to adjust the laser dot position. 11. Once the laser dot is adjusted to the correct place press the button “OK” to store the outer laser position. 12.
  • Page 141 C127 Store data in USB stick Special function: None Description: This service code will enable/disable the presence of the option inside F6 menu that can allows to copy all the content of the temp folder from the embedded pc to an USB Stick (debug/service use only). On selection the current status is displayed (0 / 1).
  • Page 142 Third Step At the end of the calibration process the machine will reboot itself. Comments: The setting must be stored to persistent memory by performing code C90. C131 Lift calibration Options: None Special function: None Description: Step 1 Lift in low position. Value must 1.51. Press “ENTER”...
  • Page 143 C132 Lift Diagnostic Options: None Special function: None. Description: Use this C code to diagnose the wheel lift. ANALOG HANDLE UP / DOWN: Percentage of applied force with respect to the maximum value of the resistance present in the handle. In rest position must be 0.
  • Page 144 CHAPTER 7 TROUBLE SHOOTING FLOW CHART FAULT 1: The balancer shows weight chasing Is the machine correctly installed? Install the machine correctly. Arethe cones, sleeve/wing nut, cap Replace the worn / defective parts. and shaft in good condition? Does the operator follow the correct Show to the operator the correct balancing procedures? balancing procedure.
  • Page 145 Is the sonar sensor fi ne Is the wheel guard switch with C82? correctly adjusted@ 4.22.? R e p l a c e t h e sonar sensor, Adjust the wheel guard switch @4.24. Calibrate with C81, 82, @ 4.22.? Does the machine C122.
  • Page 146 FAULT 2: Sonar reads incorrect rim width Are the sonar cable / Replace the cable. Does the ma- connector fi ne? chine work fi ne? Is the wheel guard correctly Adjust the wheel guard. Does the machine work fi ne? adjusted? Replace the sonar.
  • Page 147 FAULT 4: Turning the machine on, the LCD display does not show anything Supply with the correct power. Is the power supply correct? Does the machine work fi ne? Install better the wire on the plug. Are the wires well installed Does the machine work fi...
  • Page 148 FAULT 5: The laser pointer is not shoting the laser dot correctly. I s t h e l a s e r p o i n t e r Perform the C81 and C122. Does calibrated? the machine work fi ne? Is the laser pointer well Mount the pointer properly.
  • Page 150 UPDATING GUIDE: Author: Stefano Muzzioli REVISION A September 2020 Copyright statement This manual and the materials contained within are copyright protected. The manual, or any section, page, drawing, or diagram, may not be reproduced by any means without the written consent.
  • Page 152 Notice: The information contained in this document is subject to change without notice. Hofmann makes no warranty with regard to present documentation. Hofmann shall not be liable for errors contained here- in or for incidental consequential damages in connection with furnishings, performance, or use of this material.